Thermoformable laminate structure

Abstract

A moisture-resistant, moldable, thermoformable laminate structure and method of making same is disclosed. The structure comprises a layer of a foamed thermoplastic material having first and second surfaces and a coating of acrylic resin, having a softening temperature greater than approximately 130° C., impregnated fabric bonded to said first and second surfaces.

We claim: 
     
       1. A moisture-resistant, moldable, thermoformable laminate structure comprising: (a) a layer of a foamed thermoplastic material, said layer having first and second surfaces; and   (b) a coating bonded to said first and second surfaces; said coating being a resin impregnated fabric; said resin being an acrylic resin having a softening temperature greater than approximately 130° C.   
     
     
       2. The laminate structure of claim 1 wherein the layer of foamed thermoplastic material is selected from a group consisting of foamed polystyrene, foamed styrene-maleic anhydride polymer and foamed polyethylene. 
     
     
       3. The laminate structure of claim 1 wherein the layer of foamed thermoplastic material is a foamed polystyrene. 
     
     
       4. The laminate structure of claim 1 wherein said fabric is a non-woven material. 
     
     
       5. The laminate structure of claim 1 wherein said fabric is a woven cloth fabric. 
     
     
       6. The laminate structure of claim 1 wherein said fabric is a non-woven, spunbonded fabric. 
     
     
       7. The laminate structure of claim 1 wherein said acrylic resin is styrene-methacrylic acid copolymer. 
     
     
       8. A method of fabricating a moisture-resistant, moldable, thermoformable laminate structure comprising: (a) producing a layer of foamed thermoplastic material having first and second surfaces;   (b) impregnating fabric with an acrylic resin dissolved within a solvent, the resin having a softening temperature greater than 130° C.;   (c) drying the resin impregnated fabric; and   (d) bonding the resin impregnated fabric to the thermoplastic material to form a laminate structure.   
     
     
       9. The method of claim 8 wherein resin impregnated fabric is adhesively bonded to the first and second surfaces of the layer of foamed thermoplastic material. 
     
     
       10. The method of claim 8 wherein said resin impregnated fabric is heated to a temperature between approximately 130° C. and approximately 180° C. to remove the solvents from the acrylic resin. 
     
     
       11. The method of claim 8 wherein the acrylic resin is a styrene-methacrylic acid copolymer.